Improvement in processes, patterns



L. L. LEATHERS -& F. CHAPPE'LLET.

PROCESS, PATTERN AND MOLD FOR MANUFACTURING ARTIFICIAL I STONE,IN IMITA'IION 0F MOSAICS.

Na,178,308. Patented June 6; 1876.

Inventors azgm Vitnesses UNITED STATES- PATENT QFFICE.

LLEWELLYN L. LEATHEES AND FELIX OHAPPELLET, OF OAKLAND, GAL.

IMPROVEMENT IN PROCESSES, PATTERNS. AND MOLDS FOR MANUFACTURING ARTIFICIAL STONE IN IMITATIONOF MOSAICS.

Specification forming part of Letters Patent N 0. 178,308, dated J nne 6, 1876 application filed March 13, 1876.

To all whom it may concern:

Be it known that W6,LLEW'ELLYN L. LEATH- ERS and FELIX CHAPPELLET, of Oakland, Alameda county, State of California, have invented a Process for Manufacturing Imitation Mosaics on Artificial Stone; and do hereby declare the following description and accompanying drawings are sufficient to enable any person skilled in the art or science to which it most nearly appertains to make and use my said invention without further invention or experiment,

Our invention relates to a novel process and apparatus by which we are able to manufacture artificial stone in imitation of mosaics, without increasing the expense of manufacture, and with but little additional manipulation or handling, other than is required in the manufacture of the plain artificial stone.

, Referring to the accompanying drawing for a more full explanation of our invention, Figure 1 is a perspective View, showing the mold filled. Fig. 2 is a View, showing the movable shell or pattern.

Let A represent a mold, in which it is desired to cast or form a block of artificial stone by tamping or otherwise.

In manufacturing our artificial mosaic stone, we first prepare a mixture of cement and sand, either simply or in combination with other materials or ingredients, such as is used in the manufacture of plain artificial stone, and after separating the mixture into batches we add to each batch the proper coloring agent or substance to give it the desired color or tint, so that we will then have a batch of material for each color it is desired to use in forming the figure on the surface of the stone. \Ne then employ a pattern -mold, which is constructed with compartments so as to form a skeleton frame, each compartment representing one of the figllleS or designs to be incorporated in the finished surface of the block to be made.

In the drawing, Fig. 2 represents this skeleton pattern, consisting of an outer rim or frame, U, inside of which are secured intersecting partitions, which are composed of thin sheet-metal strips secured vertically inside of the frame, so as to form compartments d (1, corresponding with the various figures or designs in which the stone is to be finished, thus forming a number of compartments, each of which represents a figure or design. In molding or casting the stone we can either build up the main body or thickness of the stone by tamping in the mold in the ordinary way, and then apply the mosaic imitation on the top in finishing the block, or'we can first make the imitation mosaic in the bottom of the mold and then build up the block upon the mosaic as most convenient. We prefer to make the imitation of mosaics in the bottom of the mold, and then build the body of the block upon it, as the materials in the compartment are united better by the subsequent tamping than if the mosaics were made in the finishing of the block, and, besides, the process can be accomplished on a smooth level surface without trouble. We, therefore, in manufacturing the block, first place the skeleton frame 0 in the bottom of the mold, and fill into the Various compartments the different colored concrete or mixture in the proper or desired order, and then we ram or tamp the material in each compartment until it is properly condensed and united.

For tampin g the materials in these compartments we use a rammer, which is provided with pistons which correspond with the shape of the compartments, so that the material in each and all of the compartments is tamped at the same time. I

When the material in the compartments is properly condensed or tamped, we raise the skeleton frame slightly, again fill the compartments, and proceed with the tamping, and thus proceed until we obtain the desired thickness of the imitation mosaic.

As the mold is raised and the tamping proceeded with, the material below the frame or partitions is gradually united by the tamping so as to form a solid homogenous surface of various colored materials, disposed in regular figures and separated by distinct and sharp lines without joint or crack. 7

When the desired thickness of mosaic surface is produced, we remove the pattern-mold and fill in the concrete or artificial-stone mix ture indiscriminately, and tamp in the usual way until the block is finished.

The manipulation of the material as above stated could be reversed-that is, the body of the stone could be tamped in the usual way in the mold, and the mosaic patterns formed on the top; but it would require greater care in the fiuishin g. i

If desired, the colors could be continued throughout the thickness of the block, and thus render the stone ornamental as long as it lasts. We are thus able to prepare blocks, slabs, and other articles of artificial -stone manufacture, with ornamental surfaces in imitation of mosaics, in any desired figure or design with but little additional trouble and expense over the cost of the plain artificial stone. This process can be applied in the manufacture of any of the various kinds of artificial stone, no difference what their ingredients may be. It is desirable, however, to use a mixture which will not set too suddenly, so that the colors can be thoroughly united after the pattern-mold is raised.

Having thus described our invention, whatwe claim, and desire to secure by Letters Patent is v 1: The process of manufacturing artificial stone and other equivalent blocks, slabs, or

articles in imitation of mosaics, the same consisting in filling the diit'ferently-colored materials into the separate compartments of a pattern or compartment mold, so as to unite the contents of the compartments below the mold, substantially as above specified.

2. A pattern or compartment mold, consisting of the frame or rim G, with its intersecting cross-partitions d (1, arranged to form characters, designs, or figures, in combination 

